Performance Analysis of Defect-Free Sand Casting by Optimizing Various Process Parameters

The primary objective of this research is to identify and optimize the most influential parameters of the green sand-casting process to minimize defects in valve body components. Common defects such as shrinkage porosity, blowholes, sand inclusion, and low hardness significantly impact productivity and quality. This study employs the Taguchi approach to parameter design, utilizing Minitab 18 for Design of Experiments (DoE) and AutoCAST software for simulation. By selecting optimal levels for parameters like filling temperature and pouring time, the study aims to reduce casting rejections and achieve a “zero defect” concept in manual foundry operations.